Methodology and Approach- Part 2- Quality Inspection Manual

Quality Inspection Manual for Aluminum Formwork-Based Construction

This manual aims to ensure consistent, high-quality standards for all aspects of aluminum
formwork-based construction, contributing to safer, more durable, and efficient building projects.
Regular updates to this manual are recommended based on project learnings, industry standards,
and feedback from inspections.
We are committed to comply with the Quality Inspection Manual and ensure that the
Construction is to the standard. If we win this project, we are devoted to adhere to every
procedure that will ensure the quality of the project.

1. Introduction
 Purpose: Establish standardized procedures for inspecting quality across all phases of
construction using aluminum formwork.
 Scope: Applicable to all aluminum formwork installations, including foundation, walls,
beams, slabs, and staircases.
 Objectives:
o Ensure compliance with design specifications and safety standards.

o Enhance durability, precision, and finish quality in structural components.

o Minimize defects, formwork adjustments, and ensure consistency in casting.

2. Roles and Responsibilities

 Site Engineer: Supervises formwork installation, checks alignment and quality, and
coordinates with quality inspectors.
 Quality Inspector: Verifies formwork conditions, conducts inspections at various stages,
and prepares quality assurance reports.
 Project Manager: Oversees all inspection processes, ensures timely completion of
quality checks, and approves corrective actions.
3. Standards and Reference Documents
 Applicable Standards:
o ASTM International standards for formwork and concrete casting.

o Relevant building codes and local regulations.

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o Manufacturer's guidelines for handling and assembling aluminum formwork.

 Reference Documents:
o Approved design drawings and construction schedule.

o Manufacturer’s installation manual.

o Safety guidelines and personal protective equipment (PPE) standards.

4. Inspection Criteria and Checkpoints

4.1 Pre-Installation Checks
 Material Inspection:
o Check aluminum formwork components for any visible defects (e.g., dents,
cracks, or deformation).
o Confirm material grade, thickness, and quality per specifications.

 Dimensional Accuracy:
o Measure panel dimensions to ensure compliance with design requirements.

o Inspect alignment guides, connectors, and pins for proper fit.

 Formwork Cleanliness:
o Ensure all formwork components are free from debris, rust, and oil to maintain a
smooth concrete finish.
 Protective Coatings:
o Confirm protective coating is intact to prevent aluminum from corrosion.

4.2 Formwork Assembly Inspection

 Panel Alignment:
o Verify horizontal and vertical alignment of formwork panels.

o Ensure that all panels are securely connected and leveled to prevent shifting
during casting.
 Spacing and Leveling:
o Check spacing between panels to match the approved drawings.

o Verify the leveling of panels for accurate floor and ceiling heights.

 Joint Integrity:

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o Ensure all joints are tight and sealed to prevent concrete leakage.

o Inspect seals and gaskets (if applicable) for wear or damage.

 Reinforcement Clearance:
o Confirm required reinforcement cover is maintained between formwork and rebar
as per design.
4.3 Inspection Prior to Concrete Pouring
 Structural Stability:
o Inspect for proper bracing and shoring to support formwork under the weight of
wet concrete.
o Ensure that load-bearing components are adequately secured.

 Opening and Embedment Inspection:

o Verify that provisions for openings, conduits, pipes, and other embeds are
correctly positioned.
 Dimensional Tolerances:
o Check that dimension (e.g., wall thickness, floor height) meet design tolerances.

 Waterproofing and Release Agent Application:

o Inspect the application of release agents to prevent formwork from sticking to
concrete.
 Access and Safety:
o Confirm safe access points for workers and proper PPE usage before the pour.

4.4 Post-Concrete Pour Inspection

 Initial Setting Check:
o Verify that concrete is setting evenly, and inspect for any immediate signs of
deflection or leakage.
 Formwork Removal Timing:
o Confirm removal timing matches the concrete’s curing requirements to avoid
surface damage.
 Surface Quality:
o Inspect the finished surface for honeycombing, uneven patches, or other defects.

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o Check dimensions and levels of the completed element against design

specifications.
 Dimensional Accuracy and Tolerances:
o Measure final structural dimensions to ensure compliance with design tolerances.

 Joint and Seam Inspection:

o Verify that all seams and edges are smooth, without cracks or misalignment.

5. Inspection Schedule and Frequency

 Daily Inspections:
o Formwork stability and alignment checks.

o Safety and cleanliness checks.

 Pre-Pour Inspections:
o Comprehensive checks on each formwork setup before concrete pouring.

 Post-Pour Inspections:
o Surface quality, accuracy, and stability checks immediately after formwork
removal.
 Periodic Inspections:
o Weekly inspections to ensure continued quality, especially for projects using
repeated cycles of formwork.
6. Documentation and Reporting
 Inspection Checklists:
o Utilize standardized checklists to record inspection findings for each stage.

 Inspection Reports:
o Submit detailed reports after each major inspection, including any deviations from
standards and corrective actions taken.
 Non-Conformance Reports (NCRs):
o Document and report any significant issues that do not meet quality requirements,
including actions taken to address them.
 Quality Assurance Sign-Offs:

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o Obtain sign-offs from the responsible engineer or inspector upon completion of

each inspection.
7. Corrective Actions and Remedial Measures
 Defect Rectification:
o Specify the procedure for handling minor and major defects, including necessary
approvals for remedial work.
 Re-Inspection Requirements:
o Define criteria for re-inspection after corrective actions are taken.

 Documentation of Corrective Actions:

o Maintain records of all corrective measures for quality assurance and compliance
tracking.
8. Safety Considerations
 Personnel Safety:
o Ensure all workers involved in formwork handling and inspection use appropriate
PPE.
 Risk Management:
o Conduct risk assessments and safety briefings for each construction phase
involving formwork.
 Emergency Protocols:
o Establish and communicate protocols for emergency situations, such as structural
failure or accidents during formwork operations.
9. Continuous Improvement
 Review Meetings:
o Hold regular meetings to review inspection results and quality metrics.

 Feedback Loop:
o Implement feedback from inspection findings to improve formwork practices in
future projects.
 Training Programs:
o Provide ongoing training for site personnel to reinforce inspection standards and
quality expectations.

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Appendix
 Sample Inspection Checklists
 Key Reference Drawings and Specifications
 Manufacturer’s Handling and Safety Guidelines
 Glossary of Terms and Acronyms

ASTM Standards we will apply to check the quality of the aluminum formwork: -
ASTM standards are essential for ensuring the quality, structural integrity, and safety of
aluminum formwork components in construction projects. Here are some key ASTM standards
that apply to aluminum materials, their structural use, and quality considerations in formwork
applications: -
1. ASTM B209 – Standard Specification for Aluminum and Aluminum-Alloy Sheet and
Plate
 Covers the requirements for aluminum and aluminum-alloy sheet and plate, which are
often used in aluminum formwork components.
 Specifies the chemical composition, mechanical properties, and tolerances for aluminum
alloy grades used in construction.
2. ASTM B221 – Standard Specification for Aluminum and Aluminum-Alloy Extruded
Bars, Rods, Wire, Profiles, and Tubes
 Provides specifications for extruded aluminum products, such as bars, rods, tubes, and
profiles, which are commonly used in aluminum formwork systems.
 Covers material grades, temper conditions, and mechanical properties required for
structural applications in formwork.
3. ASTM B308/B308M – Standard Specification for Aluminum-Alloy 6061-T6 Standard
Structural Profiles
 Specifically addresses the 6061-T6 alloy, a high-strength aluminum alloy commonly used
in structural applications like formwork.
 Defines the requirements for tensile strength, yield strength, elongation, and dimensional
tolerances.
4. ASTM B557 – Standard Test Methods for Tension Testing Wrought and Cast Aluminum-
and Magnesium-Alloy Products

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 Details test methods for tension testing aluminum and aluminum-alloy products to
determine mechanical properties.
 Ensures the materials used in formwork components meet the necessary strength and
elongation requirements for safety and performance.
5. ASTM E2871 – Standard Practice for Thermal Conductivity of Aluminum Alloys Using
Calorimeter
 Focuses on the thermal properties of aluminum alloys, which is important for
understanding heat dissipation during curing and its effects on concrete.
 Useful in formwork systems to predict how the formwork will interact with curing
concrete, affecting the concrete’s surface finish and quality.
6. ASTM E330/E330M – Standard Test Method for Structural Performance of Exterior
Windows, Doors, Skylights, and Curtain Walls by Uniform Static Air Pressure Difference
 Used to evaluate the structural performance of various aluminum-based products under
pressure.
 While developed for curtain walls and similar structures, this standard can be adapted to
assess the structural behavior of aluminum formwork under loading.
7. ASTM D635 – Standard Test Method for Rate of Burning and/or Extent and Time of
Burning of Plastics in a Horizontal Position
 Evaluates the flammability of materials that may be used as coatings on aluminum
formwork.
 Ensures safety compliance for fire resistance, particularly when aluminum formwork has
protective coatings.
8. ASTM C1550 – Standard Test Method for Flexural Toughness of Fiber-Reinforced
Concrete (Using Centrally Loaded Round Panel)
 Although primarily a concrete test, it’s relevant for assessing the compatibility of
formwork with concrete types, ensuring the aluminum formwork can withstand the loads
imposed by fiber-reinforced concrete.
9. ASTM A1003/A1003M – Standard Specification for Steel Sheet, Carbon, Metallic- and
Nonmetallic-Coated for Cold-Formed Framing Members
 While this standard covers steel, it’s helpful for projects using hybrid aluminum and steel
formwork. It addresses the use of non-metallic coatings for corrosion resistance, which is
relevant for protective finishes on aluminum formwork.

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10. ASTM E139 – Standard Test Methods for Conducting Creep, Creep-Rupture, and
Stress-Rupture Tests of Metallic Materials
 Provides test methods for assessing long-term behavior under load, which can help
determine the durability of aluminum formwork under prolonged stresses.

Additional ASTM Standards for Surface Coatings (for Corrosion Protection)

If aluminum formwork components are coated for corrosion resistance, the following standards
apply:
 ASTM B117 – Standard Practice for Operating Salt Spray (Fog) Apparatus
 ASTM D1654 – Standard Test Method for Evaluation of Painted or Coated Specimens
Subjected to Corrosive Environments
These ASTM standards ensure aluminum formwork systems meet safety, durability, and
structural integrity requirements, helping maintain quality and safety across construction
projects.